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DT GCSE AQA > Material production > Flashcards

Material production Flashcards

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1
Q

what is lamination

A

a process in which one or more layers are added to a material to form a composite
- often used to increase strength and rigidity

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2
Q

examples of when laminations used in material

A
  • foam core board and corrugated card, which are stronger and stiffer than any other types of cardboard with a single layer of material
  • plywood - made up of layers of wood that are glued together to resist bending forces
  • delicate fabrics - laminated for extra strength, stiffness and protection
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3
Q

what are interfacings

A
  • extra layers of fabric stuck or sewn onto the inside of products
  • used to improve functionality and aesthetics
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4
Q

examples of when interfacings are used

A
  • in collars, cuffs ,pockets or waistbands, anywhere that needs extra strength or rigidity
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5
Q

what is webbing

A
  • when a fabric is woven in a way that gives a very high tensile strength
  • used in situations where it will be under tension such as in tow ropes, climbing harnesses
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6
Q

what is bending used for

A
  • to reinforce and stiffen material
  • eg the middle fluted layer of corrugated card is made from a series of bend that add strength which is important for packaging heavy loads
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7
Q

what is folding

A

the bending of flexible material so that the two sides of the bend are flat against each other and a line called a crease or fold occurs between them.
- used to make a material more flexible

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8
Q

what is one off / bespoke product

A

a type of production where every item will be different in order to meet a customers exact requirements

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9
Q

examples of when one off production would be used

A
  • making a wedding dress
  • making made to measure furniture
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10
Q

disadvantages of one off production

A
  • workforce needs to be highly skilled, especially if design is quite detailed so it’s an expensive way to make things
  • the type of production is very labour intensive so it takes a lot of time to make each product
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11
Q

advantages of one off production

A
  • prototypes for a new product are normally produced as a one off
  • so if the prototype works well, the product may then be manufactured in greater volumes
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12
Q

what is batch production

A

where a specific quantity of a product is made

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13
Q

advantages of batch production

A
  • you do one process on the whole batch then another process, so it’s quicker than doing one off
  • they can be used to manufacture loads of one product then a load of another
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14
Q

examples of things that use batch production

A
  • PCBs - cos different electronic products require different PCB designs
  • Templates, jigs and moulds
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15
Q

advantages of mass production

A
  • designs are less detailed so can help achieve consistency
  • workforce doesn’t need as much skill as one off
  • less labour intensive than one off
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16
Q

disadvantages of batch production

A

the machinery and workforce used need to be flexible and be able to quickly change
- the time between batches, when machines and tools may have to be set up differently or changed, wastes money as they’re not making anything they can sell

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17
Q

what is mass production

A

making a large amount of the same product

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18
Q

examples of things that are produced using mass production

A

newspapers
magazines
cars

19
Q

when would you use mass production

A

for a mass market product - when lots of people want the same thing

20
Q

advantages of mass production

A
  • stages of production broken down into simple repetitive tasks, improves consistency
  • each worker only does a small part of the process, makes job quicker
  • products have basic designs to make production simpler
  • most of the staff don’t need to be highly skilled so recruitment is easy
21
Q

disadvantages of mass production

A

they often use expensive specialised equipment and CAD and CAM

22
Q

what is continuous production

A

production that runs all the time, without interruption, 24 hours a day
- as it would be too expensive to keep stopping and restarting the process

23
Q

disadvantages of continuous production

A
  • expensive
24
Q

advantages of continuous production

A
  • pretty much entirely automated, meaning very few workers are needed
  • can be designed to be very efficient , so the cost per item is cheap
  • used to make products such as aluminium foil and chemicals
25
Q

what does quality control involve

A

testing materials products or components to check they’ve been made to a high enough standard and they meet the manufacturing specification

26
Q

how comes only a sample of the materials are tested when carrying out quality control

A

it would take too much time to check them all

27
Q

why is it important that the dimensions of components are accurate

A

if they aren’t, the parts won’t fit together properly when the product is assembled

28
Q

what is tolerance (simple definition)

A

the margin of error that is considered to be acceptable and won’t affect the product’s functionality

29
Q

why should tolerances be included on working drawings

A

to show the limits within which the product should be manyfactured

30
Q

what are go/no go fixtures

A

they are limit gauges which check to see whether the size of a part is within its tolerance

  • theyre usually double ended - one is machines to the lower limit and the other end to the upper limit of tolerance
31
Q

advantages of using a go/no go fixture

A

the checks don’t take very long and are much quicker than measuring actual dimensions of a component

32
Q

how does a registration mark work

A

if the plates are in the right places, you get a single, clear image

If not, the registration mark will be printed, a bit fuzzy

33
Q

How do manufacturers check that repeating prints are being printed correctly onto fabrics?

A

They compare prints to an original sample print
- This is much quicker and easier to do than try to measure the dimensions of each part of the repeating pattern one at a time

34
Q

what are depth stops

A
  • long rods that are clamped close to the drill bit of some drills
  • they allow you to drill a hole to an exact depth in whatever material you are drilling
  • they nice this depth has been reached, the depth stop will come into contact with the material and will prevent you from drilling any deeper
35
Q

how should a laser cutter be programmed

A
  • needs to programmed with the right information
    eg. the dimensions of the components to be cut - so the laser cutter knows exactly where to cut
  • the correct power settings and feed rate
36
Q

what is the feed rate of a laser cutter

A

the speed that the laser moves over and cuts the material

37
Q

why is it beneficial if a laser cutter is programmed correctly

A

because then the laser cutter can cut to a tiny tolerance ( with high accuracy and precision)

38
Q

how are PCBs manufactured using photo etching

A
  • in this process, the PCB is exposed to UV light, which removes unwanted copper from the board, leaving behind the copper needed to form the tracks
39
Q

why do exposure times need to be carefully chosen when manufacturing PCBs

A
  • exposing the pcb for too long may cause the copper tracks to be removed
  • exposing it for too little time will mean that unwanted copper will remain
40
Q

once chosen, why should exposure times be kept the same for every PCB that is produced

A

to make sure all of them are of a consistent quality when output

41
Q

what is quality control

A

ensuring products are manufactured to a high enough standard

42
Q

what is a registration mark used for

A
  • normally appears as a cross shape
  • used by manufacturers to check the quality of colour printing onto paper and board
  • used to make sure the printing plates are aligned in the right position
43
Q

why should a sample still need to be checked after laser cutting

A

to make sure the machine hasn’t malfunctioned or been incorrectly programmed

DT GCSE AQA (31 decks)

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